1989 FORD FIESTA fuel additives

Lubricants and fluids
Refer to end of “Weekly Checks”
Capacities
Engine oil
At oil and filter change:HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 3.25 litres
CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
3.50 litresZetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 4.25 litres
Difference between dipstick minimum and maximum level notches . . . 0.5 to 1.0 litre
Cooling system
HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . 7.1 litresCVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 7.6 litresZetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 7.0 litres
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 42.0 litres
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 3.1 litres
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
3.5 litres
Engine
Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise (seen from right-hand side of vehicle)
Oil filter: HCS, CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion C104
Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . Champion C148
Cooling system
Coolant protection at standard 40% antifreeze/water mixture ratio:Slush point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . -25ºC (-13ºF)Solidifying point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . -30ºC (-22ºF)
Coolant specific gravity at standard 40% antifreeze/water
mixture ratio and 15ºC/59ºF - with no other additives in coolant . . . . . 1.061
Fuel system
Idle speed*: 1.0, 1.1 and 1.3 litre HCS (carburettor) engines . . . . . . . . . . . . . . . . . 750 ± 50 rpm (cooling fan running)
1.4 and 1.6 litre CVH (carburettor) engines:
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
800 ± 50 rpm (cooling fan running)CTX automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 ± 50 rpm (cooling fan running)
1.6 litre CVH (EFi fuel injection) engines: Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 900 ± 50 rpmBase idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . 750 ± 50 rpm
Idle mixture CO content*: 1.0, 1.1 and 1.3 litre HCS (carburettor) engines . . . . . . . . . . . . . . . . . 1.0 ± 0.5%
1.4 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 ± 0.25%
1.6 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 ± 0.5%
1.6 litre CVH (fuel injection) engines:Non turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 0.8 ± 0.25%
Turbo models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . 1.5 ± 0.25%
*Note: The idle speed and mixture CO content is only adjustable on the engines \
shown above. On all other engines, it is controlled by the engine
management system, and cannot be checked or adjusted without specialised\
test equipment.
Air filter element: 1.0, 1.1 and 1.3 litre HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W153
1.4 litre CVH and PTE engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W226
1.6 litre CVH (carburettor) engines . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion W226
1.6 litre CVH (fuel injection) engines . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U557
1.6 and 1.8 litre Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Champion U612
Fuel filter:
HCS, CVH (fuel injection) and PTE engines:Without quick-release fuel line fittings . . . . . . . . . . . . . . . . . . . . . . Champion L204
With quick-release fuel line fittings . . . . . . . . . . . . . . . . . . . . . . . . . Champion type not available
Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . Champion L218
1•2Servicing Specifications
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point at the engine to the end of the tailpipe.
Ideally, this should be done on a hoist, where
unrestricted access is available; if a hoist is
not available, raise and support the vehicle on
axle stands.
2Check the pipes and connections for
evidence of leaks, severe corrosion, or
damage. Make sure that all brackets and
rubber mountings are in good condition, and
tight; if any of the mountings are to be
renewed, ensure that the replacements are of
the correct type (see illustration) . Leakage at
any of the joints or in other parts of the system
will usually show up as a black sooty stain in
the vicinity of the leak. Note: Exhaust sealants
should not be used on any part of the exhaust
system upstream of the catalytic converter -
even if the sealant does not contain additives
harmful to the converter, pieces of it may
break off and foul the element, causing local
overheating.
3 At the same time, inspect the underside of
the body for holes, corrosion, open seams,
etc, which may allow exhaust gases to enter
the passenger compartment. Seal all body
openings with silicone or body putty.
4 Rattles and other noises can often be
traced to the exhaust system, especially the
rubber mountings. Try to move the system,
silencer(s) and catalytic converter. If any
components can touch the body or
suspension parts, secure the exhaust system
with new mountings.
5 Check the running condition of the engine
by inspecting inside the end of the tailpipe;
the exhaust deposits here are an indication
of the engine’s state of tune. The inside of the
tailpipe should be dry, and should vary in
colour from dark grey to light grey/brown; if it
is black and sooty, or coated with white
deposits, the engine is in need of a thorough
fuel system inspection.
13 Underbody and fuel/brake line check
1
1With the vehicle raised and supported on
axle stands or over an inspection pit,
thoroughly inspect the underbody and wheel
arches for signs of damage and corrosion. In
particular, examine the bottom of the side
sills, and any concealed areas where mud can
collect. Where corrosion and rust is evident,
press and tap firmly on the panel with a
screwdriver, and check for any serious
corrosion which would necessitate repairs. If
the panel is not seriously corroded, clean
away the rust, and apply a new coating of
underseal. Refer to Chapter 11 for more
details of body repairs.
2 At the same time, inspect the PVC-coated
lower body panels for stone damage and
general condition.
3 Inspect all of the fuel and brake lines on the
underbody for damage, rust, corrosion and
leakage. Also make sure that they are correctly supported in their clips. Where
applicable, check the PVC coating on the
lines for damage.
14 Brake check
2
Note:
For detailed photographs of the brake
system, refer to Chapter 9.
1 The work described in this Section should
be carried out at the specified intervals, or
whenever a defect is suspected in the braking
system. Any of the following symptoms could
indicate a potential brake system defect:
a) The vehicle pulls to one side when the brake pedal is depressed.
b) The brakes make scraping or dragging
noises when applied.
c) Brake pedal travel is excessive.
d) The brake fluid requires repeated topping-
up.
2 A thorough inspection should be made to
confirm the thickness of the linings, as
follows.
Front brakes
3 Chock the rear wheels then jack up the
front of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
4 For better access to the brake calipers,
remove the wheels.
5 Look through the inspection window in the
caliper, and check that the thickness of the
friction lining material on each of the pads is
not less than the recommended minimum
thickness given in the Specifications. Note:
Bear in mind that the lining material is normally
bonded to a metal backing plate.
6 If it is difficult to determine the exact
thickness of the pad linings, or if you are at all
concerned about the condition of the pads,
then remove them from the calipers for further
inspection (refer to Chapter 9).
7 Check the remaining brake caliper in the
same way.
8 If any one of the brake pads has worn down to, or below, the specified limit,
all fourpads
must be renewed as a set.
9 Measure the thickness of the discs with a
micrometer, if available, to make sure that they
still have service life remaining. If any disc is
thinner than the specified minimum thickness,
renew it (refer to Chapter 9). In any case,
check the general condition of the discs. Look
for excessive scoring and discolouration
caused by overheating. If these conditions
exist, remove the relevant disc and have it
resurfaced or renewed (refer to Chapter 9).
10 Before refitting the wheels and lowering
the car, check all brake lines and hoses (refer
to Chapter 9). In particular, check the flexible
hoses in the vicinity of the calipers, where
they are subjected to most movement. Bend
them between the fingers (but do not actually
bend them double, or the casing may be
damaged) and check that this does not reveal
previously-hidden cracks, cuts or splits.
Rear brakes
11 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
12 For better access, remove the rear
wheels.
13 To check the brake shoe lining thickness
without removing the brake drums, prise the
rubber plugs from the backplates, and use an
electric torch and mirror to inspect the linings
of the leading brake shoes. Check that the
thickness of the lining material on the brake
shoes is not less than the recommendation
given in the Specifications.
14 If it is difficult to determine the exact
thickness of the brake shoe linings, or if you
are at all concerned about the condition of the
shoes, then remove the rear drums for a more
comprehensive inspection (refer to Chap-
ter 9).
15 With the drum removed, check the shoe
return and hold-down springs for correct
installation, and check the wheel cylinders for
leakage of brake fluid. Check the friction
surface of the brake drums for scoring and
discoloration. If excessive, the drum should
be resurfaced or renewed.
16 Before refitting the wheels, check all
brake lines and hoses (refer to Chapter 9). On
completion, apply the handbrake and check
that the rear wheels are locked. The
handbrake also requires periodic adjustment,
and if its travel seems excessive, refer to
Section 27.
15 Roadwheel nut tightness check
1
1Apply the handbrake.
2 Remove the wheel covers, using the flat
end of the wheelbrace supplied in the tool kit
(on some models it will be necessary to
unscrew the retaining bolts with a special
key).
Every 10 000 miles or 12 months1•17
12.2 Ensure that the exhaust system
rubber mountings replacements are of the correct type - their colour is a good guide. Those nearest to the catalytic converterare more heat-resistant than the others
1
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d)Refit the remaining parts in the reverse
order of removal. Tighten all fasteners to
the specified torque wrench settings
where given.
e) Where drained, refill the cooling system (see Chapter 1).
f) Run the engine, and check for exhaust
leaks. Check the coolant level when fully
warmed-up to normal operating
temperature.
4 Catalytic converter - general
information and precautions
The catalytic converter is a reliable and
simple device, which needs no maintenance
in itself, but there are some facts of which an
owner should be aware if the converter is to
function properly for its full service life. a) DO NOT use leaded petrol in a vehicle equipped with a catalytic converter - the
lead will coat the precious metals,
reducing their converting efficiency, and
will eventually destroy the converter.
b) Always keep the ignition and fuel systems
well-maintained in accordance with the
manufacturer’s schedule (see Chapter 1).
c) If the engine develops a misfire, do not drive the vehicle at all (or at least as little
as possible) until the fault is cured.
d) DO NOT push - or tow-start the vehicle -
this will soak the catalytic converter in
unburned fuel, causing it to overheat
when the engine does start.
e) DO NOT switch off the ignition at high engine speeds, ie do not “blip” the
throttle immediately before switching off.
f) DO NOT use fuel or engine oil additives - these may contain substances harmful to
the catalytic converter.
g) DO NOT continue to use the vehicle if the
engine burns oil to the extent of leaving a
visible trail of blue smoke.
h) Remember that the catalytic converter
operates at very high temperatures. DO
NOT, therefore, park the vehicle in dry
undergrowth, over long grass or piles of
dead leaves, after a long run.
I) Remember that the catalytic converter is FRAGILE. Do not strike it with tools
during servicing work.
j) In some cases, a sulphurous smell (like
that of rotten eggs) may be noticed from
the exhaust. This is common to many
catalytic converter-equipped vehicles.
Once the vehicle has covered a few
thousand miles, the problem should
disappear. Low quality fuel with a high
sulphur content will exacerbate this effect.
k) The catalytic converter used on a well-
maintained and well-driven vehicle should
last for between 50 000 and
100 000 miles. If the converter is no
longer effective, it must be renewed.
5 Positive crankcase ventilation system - checking
and component renewal
2
Checking
1 Checking procedures for the system
components are included in Chapter 1.
Component renewal - all
engines except Zetec
Air cleaner components
2 See Chapter 1.
Filter/oil separator and hoses
3All the components relating to the positive
crankcase ventilation system, with the
exception of the HCS engine filter/adapter
located on the underside of the air cleaner,
may be removed by simple disconnection and
withdrawal (having noted all connections for
subsequent refitting).
4 The refitting of all components is a reversal
of the removal procedure, ensuring that the
connections are correctly made.
Component renewal - Zetec
engines
Air cleaner components
5 See Chapter 1.
Positive Crankcase Ventilation (PCV)
valve
6The valve is plugged into the oil separator
on Zetec engines (see illustration).Depending on the tools available, access to
the valve may be possible once the pulse-air
assembly has been removed (see Section 7).
If this is not feasible, proceed as outlined in
paragraph 7 below.
Oil separator
7
Remove the exhaust manifold (see Sec-
tion 3). The positive crankcase ventilation
valve can now be unplugged and flushed, or
renewed, as required, as described in Chap-
ter 1.
8 Unbolt the oil separator from the cylinder
block/crankcase, and withdraw it; remove and
discard the gasket.
9 Flush out or renew the oil separator, as
required (see Chapter 1).
10 Refitting is the reverse of the removal
procedure, but use a new gasket between the
oil separator and cylinder block. Refill the
cooling system (see Chapter 1). Run the
engine, check for exhaust leaks, and check
the coolant level when it is fully warmed-up.
6 Evaporative emissions control system - checking
and component renewal
2
Checking
1 Poor idle, stalling and poor driveability can
be caused by an inoperative canister-purge
solenoid valve, a damaged canister, split or
cracked hoses, or hoses connected to the
wrong fittings. Check the fuel filler cap for a
damaged or deformed gasket.
Exhaust and emission control systems 4E•5
5.6 Crankcase emission control system (Zetec engine models)
1 Oil separator
2 Gasket
3 Positive crankcase ventilation (PCV) valve 4 Cylinder block/crankcase opening
5 Crankcase breather pipe and flexible
hoses
4E
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